Pad and method for manufacturing pad

Abstract

To provide a new pad and a method for manufacturing the pad.SOLUTION: A pad according to the present disclosure includes a first layer, a thread-like member, and a second layer. The first layer has a back surface and a front surface opposite the back surface. The thread-like member penetrates the first layer and has a plurality of loop parts and an engaging part. The plurality of loop parts protrudes from the front surface. The engaging part connects the plurality of loop parts and is at least partially disposed on the back surface. The second layer includes a foam material and is bonded to the back surface.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a pad and a method for manufacturing the pad. [Background technology]

[0002] Conventionally, sleeper pads having protrusions on their surfaces have been known. The protrusions of such pads are embedded in the concrete sleepers formed on the pads to prevent the pads from falling off the concrete sleepers (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6674504 Summary of the Invention [Problem to be solved by the invention]

[0004] Such a pad preferably has a protruding portion shaped to prevent it from peeling off from the attached member (a concrete sleeper in the example of Patent Document 1), and further has a structure that makes it difficult for the protruding portion to peel off from the pad. An object of the present disclosure is to provide a novel pad and a method for manufacturing the pad. [Means for solving the problem]

[0005] The pad according to the present disclosure includes a first layer, a thread-like member, and a second layer. The first layer has a back surface and a front surface opposite the back surface. The thread-like member penetrates the first layer and has a plurality of loop portions and an engagement portion. The plurality of loop portions protrude from the front surface. The engagement portion connects the plurality of loop portions and is at least partially disposed on the back surface. The second layer includes a foam material and is bonded to the back surface.

[0006] A method for manufacturing a pad according to the present disclosure includes a step of passing a thread-like member through a first layer to form a plurality of loop portions and an engagement portion. The first layer has a back surface and a surface opposite the back surface. The plurality of loop portions protrude from the surface of the first layer. The engagement portion connects the plurality of loop portions and is at least partially disposed on the back surface. The method for manufacturing a pad according to the present disclosure further includes a step of foaming a foam material to form a second layer, and a step of bonding the first layer and the second layer, which are integrated with the thread-like member.

[0007] With this pad, a loop portion protruding from the surface of the first layer can be disposed between the pad and the attachment member. This prevents the pad from peeling away from the attachment member. Also, with this pad, an engagement portion exposed on the back surface of the first layer can be disposed between the back surface of the first layer and the second layer. This prevents the first layer from peeling away from the second layer. Furthermore, with this pad manufacturing method, a pad having a loop portion and an engagement portion formed in the first layer can be manufactured easily and efficiently. [Effects of the Invention]

[0008] According to the present disclosure, a novel pad and a method for manufacturing the pad can be provided. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 2 is a perspective view of a pad according to an embodiment of the present disclosure. [Figure 2] 1 is a cross-sectional view of a pad according to an embodiment of the present disclosure. [Figure 3] FIG. 10 is a cross-sectional view of a pad according to another embodiment of the present disclosure. [Figure 4] 1A to 1C are schematic diagrams illustrating a method for manufacturing a pad according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. Fig. 1 is a perspective view showing an outline of a pad 1 according to an embodiment of the present disclosure. In Fig. 1, the up-down direction H is defined as the upper side of the paper and the lower side, but does not necessarily coincide with the actual direction of gravity. Fig. 2 is a cross-sectional view showing an outline of the cross section of the pad 1 taken along the line AA in Fig. 1.

[0011] As shown in FIG. 1 , the pad 1 has a predetermined length in a width direction (an example of a first direction) W, a depth direction (an example of a second direction) D, and a vertical direction H. The pad 1 in this embodiment is formed in a substantially rectangular parallelepiped shape and is used as a sleeper pad for a railway. Specifically, ready-mixed concrete for the sleepers is poured onto the upper side of the pad 1 in the vertical direction H and allowed to harden, thereby bonding the pad 1 and the sleepers together. The pad 1, with the pad 1 and the sleepers integrated together, is placed on the railway track as a vibration-proofing and sound-proofing material.

[0012] The pad 1 can be formed into a variety of sizes and shapes depending on the intended use. For example, the pad 1 may be used as a wall material for vibration and sound insulation in a residential building, or as a damper disposed between an electric machine and a floor. In this case, the pad 1 is disposed as a vibration and sound insulation material with a mounting member adhered to the upper side in the vertical direction H.

[0013] As shown in FIG. 1, the pad 1 includes a first layer 2, a plurality of thread-like members 4, a second layer 6, and a third layer 8.

[0014] The first layer 2 has a back surface 21 and a front surface 22 opposite the back surface 21. In this embodiment, the first layer 2 is a woven fabric including a woven fabric material. The first layer 2 is arranged such that the front surface 22 is on the upper side in the vertical direction H and the back surface 21 is on the lower side in the vertical direction H. Therefore, in this embodiment, the front surface 22 of the first layer 2 directly becomes the upper surface of the pad 1.

[0015] As shown in FIG. 2 , the thread-like members 4 include resin threads and are sewn through the first layer 2. In this embodiment, the thread-like members 4 are sewn into the first layer 2, which has been prepared in advance, using an industrial sewing machine or the like. Alternatively, the thread-like members 4 may be knitted into the first layer 2 at the same time as the first layer 2 is prepared. The thread-like members 4 are sewn continuously from one end to the other end of the first layer 2 along the width direction W. The thread-like members 4 may be sewn into the first layer 2 along the depth direction D, or may be sewn diagonally with respect to the width direction W and the depth direction D.

[0016] The thread-like members 4 may be arranged at intervals in a direction intersecting the direction in which they are sewn into the first layer 2. In this embodiment, the thread-like members 4 are arranged evenly at regular intervals in the depth direction D.

[0017] The thread-like member 4 has a plurality of loop portions 41 and an engaging portion 42 .

[0018] The loop portion 41 protrudes from the surface 22 of the first layer 2. That is, an upper portion 411 of the loop portion 41 is spaced upward in the up-down direction H from the surface 22 of the first layer 2. The loop portion has a width 412 and a height 413. In this embodiment, the width 412 of the loop portion 41 is substantially the same as the height 413. Furthermore, the interval 414 between adjacent loop portions 41 of one thread-like member 4 may be determined based on the width 412 and height 413 of the loop portion 41. However, the size of the loop portion 41 can be changed in various ways depending on the use and shape of the pad 1. In this embodiment, a plurality of loop portions 41 are formed for one thread-like member 4. That is, a plurality of loop portions 41 for one thread-like member 4 are regularly arranged at intervals 414 in the width direction of the first layer 2.

[0019] With this configuration, the multiple loop portions 41 of the pad 1 are fixed in a state where they are embedded in the ready-mixed concrete during the process of forming the sleeper from ready-mixed concrete. As a result, a layer in which the multiple loop portions 41 are embedded in the concrete is formed between the pad 1 and the sleeper. This makes it possible to prevent the pad 1 and the sleeper, which are formed integrally, from peeling off from each other.

[0020] In this embodiment, the loop portion 41 of the pad 1 used as a sleeper pad is formed so that the width 412 is about 2 mm, the height 413 is about 3 mm, and the spacing 414 between adjacent loop portions 41 is about 3 mm.

[0021] The engaging portion 42 connects the multiple loop portions 41. The engaging portion 42 is at least partially disposed on the back surface 21. In this embodiment, the engaging portion 42 is disposed between two adjacent loop portions 41 to connect the two adjacent loop portions 41. The engaging portion 42 includes a first portion that is continuous with an end of one loop portion 41 and penetrates from the front surface 22 to the back surface 21 of the first layer 2, a second portion that is disposed and exposed on the back surface 21, and a third portion that penetrates from the back surface 21 to the front surface 22 and connects to the loop portion 41 disposed adjacent to the one loop portion 41. A portion 421 of the engaging portion 42 is disposed with a predetermined length 422 exposed on the back surface 21.

[0022] In this embodiment, the engagement portion 42 penetrates along the up-down direction H, i.e., perpendicularly to the first layer 2. Therefore, the predetermined length 422 of the engagement portion 42 is approximately the same as the interval 414 between adjacent loop portions 41. However, the angle at which the engagement portion 42 penetrates the first layer 2 can also be changed to various degrees depending on the application and shape of the pad 1.

[0023] A portion 421 of the engaging portion 42 is disposed between the back surface 21 of the first layer 2 and the second layer 6, which will be described later. As a result, the first layer 2 and the second layer 6 are bonded together, with the portion 421 of the engaging portion 42 wrapped around them. Therefore, the portion 421 of the engaging portion 42 can prevent the first layer 2 and the second layer 6 from peeling off. Furthermore, since the engaging portion 42 is disposed between the first layer 2 and the second layer 6 and bonded together, the thread-like member 4 can be prevented from falling off the first layer 2. This can prevent the loop portion 41 of the thread-like member 4 from unintentionally falling off and becoming deformed on the surface 22 of the first layer 2.

[0024] A part 421 of the engagement portion 42 does not protrude from the rear surface 21, but is exposed along the rear surface 21. The size 422 of the engagement portion 42 exposed on the rear surface 21 may be determined based on the width 412, height 413, and interval 414 of the loop portion 41. However, the size of the engagement portion 42 can be changed in various ways depending on the use and shape of the pad 1.

[0025] In this embodiment, the engaging portion 42 of the pad 1 used as a sleeper pad is formed so that the size 422 exposed on the back surface 21 is approximately 3 mm.

[0026] The loop portions 41 and the engaging portions 42 are alternately and continuously arranged in the first layer 2 from one end to the other end in the width direction W, which is the direction in which the thread-like member 4 extends. That is, in this embodiment, one thread-like member 4 is sewn in without interruption from one end to the other end in the width direction W of the first layer 2, and the loop portions 41 and the engaging portions 42 are alternately arranged regularly.

[0027] The pad 1 may include a plurality of thread-like members 4. The plurality of thread-like members 4 may be arranged in parallel or may intersect. In this embodiment, as shown in FIG. 1 , the plurality of thread-like members 4 are arranged at predetermined intervals 43 in the depth direction D. On the surface 22 of the first layer 2, the loop portions 41 of one thread-like member 4 are regularly arranged at predetermined intervals 414 along the width direction W, and the loop portions 41 of a plurality of thread-like members 4 are regularly arranged at predetermined intervals 43 along the depth direction D. That is, in this embodiment, the loop portions 41 of the plurality of thread-like members 4 are regularly arranged at equal intervals in the width direction W and the depth direction D on the surface 22 of the first layer 2.

[0028] Furthermore, adjacent thread-like members 4 in the depth direction D may be arranged such that the centers 415 of their loop portions 41 are spaced apart along the width direction W, or may be arranged so that they coincide with each other in the width direction W. As shown in FIG. 2 , in this embodiment, adjacent thread-like members 4 in the depth direction D are arranged such that the centers 415 of their loop portions 41 are spaced apart along the width direction W. Note that in FIG. 2 , for ease of understanding, the second thread-like member 4b is indicated by a dashed line. In this embodiment, adjacent first thread-like member 4a and second thread-like member 4b in the depth direction are arranged such that the centers of their loop portions 41a and 41b are spaced apart by a distance of 44 along the width direction W. That is, the second thread-like member 4b is arranged offset from the first thread-like member 4a by a distance of 44 in the width direction W. In this embodiment, the distance 44 between the loop portion 41a of the first thread-like member 4a and the loop portion 41b of the second thread-like member 4b is approximately the same as the size 412 of the loop portion 41. That is, the loop portions 41a of the first thread-like member 4a and the loop portions 41b of the second thread-like member 4b are arranged alternately along the depth direction D. As a result, the multiple loop portions 41 are arranged on the surface 22 of the first layer 2 of the pad 1, evenly distributed in the width direction W and the depth direction D.

[0029] The second layer 6 includes a foam material. In this embodiment, the second layer 6 is a foam molded member made by foaming polyurethane. The second layer 6 is molded to be thicker in the up-down direction H than the first layer 2 and the third layer 8 (described later). In this embodiment, the second layer 6 is formed to have the same size as the first layer 2 in the width direction W and the depth direction D. The second layer 6 is also formed to a thickness of approximately 5 mm to 200 mm, uniform in the width direction W and the depth direction D. However, the thickness of the second layer 6 can be varied in a variety of ways depending on the application and shape of the pad 1.

[0030] The third layer 8 includes a nonwoven fabric material. In this embodiment, the third layer 8 is a nonwoven fabric. The third layer 8 is formed to have a thickness in the up-down direction H that is equal to or greater than that of the first layer 2. The third layer 8 is not limited to this, and may include a metal plate, film, or the like. In this embodiment, the third layer 8 is formed to have the same size as the first layer 2 and the second layer 6 in the width direction W and the depth direction D. The third layer 8 is also formed to have a thickness of approximately 5 mm, uniform in the width direction W and the depth direction D. The thickness of the third layer 8 can be varied in various ways depending on the use and shape of the pad 1. The third layer 8 may also be omitted depending on the use and shape of the pad 1.

[0031] Next, a pad 10 according to another embodiment of the present disclosure will be described with reference to Fig. 3. In the description of this embodiment, only the differences from the pad 1 of the embodiment shown in Fig. 2 will be described.

[0032] As shown in FIG. 3 , in this embodiment, the engagement portion 42 penetrates from the front surface 22 to the back surface 21 of the first layer 2, continuing from the loop portion 41, and is exposed on the back surface 21 in multiple sections. In this embodiment, the engagement portion 42 is exposed on the back surface 21 over a predetermined length 423, then folded back inside the first layer 2, and then again exposed on the back surface 21 over the predetermined length 423. That is, while the embodiment of FIG. 2 exposes the engagement portion 42 once on the back surface 21 for one loop portion 41 over the length 422, this embodiment differs in that the engagement portion 42 is exposed twice on the back surface 21 for one loop portion 41 over the length 423. In this embodiment, the engagement portion 42 is formed so that the length 423 is approximately 1.5 mm. As a result, the engagement portion 42 is disposed between the back surface 21 of the first layer 2 and the second layer 6, preventing the first layer 2 and the second layer 6 from peeling apart.

[0033] However, the length 423 of the engaging portion 42 exposed on the back surface 21 of the first layer 2 can be changed to various lengths depending on the application and shape of the pad 1. In addition, the number of times the engaging portion 42 is folded back inside the first layer 2, i.e., the number of times the engaging portion 42 is exposed on the back surface 21 for one loop portion 41, can also be changed to various lengths.

[0034] Next, a method for manufacturing the pad 1 according to an embodiment of the present disclosure will be described with reference to Fig. 4. As shown in Fig. 4, the method M for manufacturing the pad 1 according to the present disclosure includes a loop portion forming step M1, a foam molding step M2, a bonding step M3, a cutting step M4, and a loading step M5.

[0035] In the loop portion forming process M1, a woven fabric member that will become the first layer 2 is prepared, and thread-like members 4 are passed through the first layer 2 to form the loop portion 41 and the engagement portion 42. In this embodiment, the first layer 2 and the thread-like members 4 are formed by regularly sewing resin threads into a woven fabric member that has been formed to a predetermined size in the width direction W and depth direction D using a sewing machine. However, the first layer 2 and the thread-like members 4 may also be formed by sewing resin threads into the woven fabric member and then cutting it to a predetermined size.

[0036] Next, in the foam molding step M2, the foam material is foamed to form the second layer 6. In this embodiment, the second layer 6 is formed by a molding method in which the foam material is poured into a mold formed into a predetermined shape and foamed and heated inside the mold.

[0037] Next, in the bonding step M3, the first layer 2 and thread-like members 4 formed in the loop portion forming step M1 are bonded to the second layer 6 formed in the foam molding step M2. That is, in the bonding step M3, the back surface 21 of the first layer 2 integrated with the thread-like members 4 is bonded to the second layer 6. In this embodiment, the first layer 2 and the thread-like members 4 are bonded to the pre-formed second layer 6 to form an integrated body. Furthermore, a third layer 8, which is a nonwoven fabric, may be bonded to the second layer 6.

[0038] However, the present invention is not limited to this, and for example, the second layer 6 may be formed by a conveyor method in which foaming and heating are performed on a conveyor moving at a predetermined speed, and the first layer 2 and thread-like members 4, which are integrated with the foamed material in the middle of solidifying, may be placed to bond the second layer 6, the first layer 2, and the thread-like members 4. In this case, by placing the back surface 21 of the first layer 2, where the engaging portions 42 of the thread-like members 4 are exposed, against the foamed material in the middle of solidifying, the foam molding step M2 and the bonding step M3 can be completed simultaneously.

[0039] In this embodiment, the foam molding process M2 and the bonding process M3 are performed in stages, but the present disclosure is not limited to this. That is, when the second layer 6 is formed by the molding method, the foam molding process M2 and the bonding process M3 may be performed simultaneously. Also, when the second layer 6 is formed by the conveyor method, the foam molding process M2 and the bonding process M3 may be performed in stages. However, various methods can be used to perform the foam molding process M2 and the bonding process M3 depending on the application and shape of the pad 1.

[0040] Next, in a cutting process M4, the integrated first layer 2, thread-like members 4, second layer 6, and third layer 8 are cut to a predetermined size to form the pad 1. In this embodiment, the first layer 2, thread-like members 4, second layer 6, and third layer 8 are cut after being integrated, but this is not limiting, and the first layer 2 and thread-like members 4 formed in advance to a predetermined size may be bonded to the second layer 6 formed or cut to a predetermined size.

[0041] Finally, in the stacking step M5, at least two pads 1 are stacked with their loop portions 41 facing each other. That is, in this embodiment, two pads 1 are stacked in the vertical direction H with their surfaces 22 facing each other. As a result, the tip of the loop portion 41 of one pad 1 is placed in contact with the surface 22 of the first layer 2 of the other pad 1. At this time, the pads 1 may be stacked with a shift in the width direction W and the depth direction D so that the tips of the loop portions 41 do not contact each other. Therefore, the loop portions 41 of the two pads 1 stacked in the vertical direction H interfere with each other, restricting movement in the width direction W and the depth direction D. As a result, it is possible to prevent the two pads 1 from shifting or shifting during transportation.

[0042] In the present disclosure, at least two pads 1 are stacked in the vertical direction H, but this is not limiting, and two pads 1 may be stacked in the width direction W and the depth direction D.

[0043] As described above, the present disclosure can provide a novel pad and a method for manufacturing the pad. [Explanation of symbols]

[0044] 1(10): Pad 2: First layer 21: Back surface 22: Front surface 4: Thread-like member 41 (41a, 41b): Loop portion 42: Engagement portion 6:Second layer W: Width direction (first direction) D: Depth direction (second direction) M: Manufacturing method M1: Loop Forming Process M2: Bubble Forming Process M3: Adhesion Process M4: Cutting Process

Claims

1. a first layer having a back surface and a surface opposite the back surface; a thread-like member penetrating the first layer, the thread-like member having a plurality of loop portions protruding from the front surface and at least one engagement portion connecting the plurality of loop portions and at least partially disposed on the back surface; a second layer including a foam material and bonded to the back surface; Equipped with pad.

2. The filamentous member includes a resin yarn, and the loop portions and the engagement portions are alternately and continuously arranged. The pad according to claim 1.

3. A plurality of the filamentous members are provided, The thread-like member is arranged side by side in a second direction intersecting a first direction in which the engagement portion and the loop portion are arranged side by side. A pad according to claim 1 or 2.

4. The thread-like members adjacent to each other in the second direction are arranged such that the centers of the loop portions are spaced apart from each other along the first direction when viewed from the second direction.

4. The pad according to claim 3.

5. The thread-like member is continuous from one end to the other end of the first layer in a first direction in which the engagement portion and the loop portion are arranged side by side. A pad according to any one of claims 1 to 4.

6. a step of passing a thread-like member through a first layer having a back surface and a surface opposite to the back surface to form a plurality of loop portions protruding from the surface of the first layer and an engagement portion connecting the plurality of loop portions and at least partially disposed on the back surface; expanding the foam material to form a second layer; a step of adhering the back surface of the first layer integral with the thread-like member and the second layer; Equipped with A method for manufacturing the pad according to claim 1.

7. a step of stacking at least two of the pads, each including the thread-like member, the first layer, and the second layer, with the loop portions facing each other; Further comprising: A method for manufacturing the pad according to claim 6.

8. The first layer has a first through hole and a second through hole different from the first through hole, The loop portion is connected to a first engagement portion in the first through hole and a second engagement portion in the second through hole. A pad according to any one of claims 1 to 5.

9. The at least one engaging portion includes a first portion connected to one of the loop portions and exposed on the back surface, and a second portion connected to another of the loop portions and exposed on the back surface, an intermediate portion connected between the first portion and the second portion and located within the first layer; A pad according to any one of claims 1 to 5.

10. A vibration-damping material having a pad described in any one of claims 1 to 5 and 8 to 9.

11. A soundproofing material having a pad described in any one of claims 1 to 5 and 8 to 9.

12. A sleeper pad having a pad described in any one of claims 1 to 5 and 8 to 9.

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